Thermal contraction compensation for superconducting and cryo-resistive cables

ABSTRACT

A cable insertion tool for installing thermally compensated superconducting and cryo-resistive cables is disclosed. The cable insertion tool includes a guide tube adapted to engage a pipe and to prevent a cable positioned therein from buckling, a cross-bar adapted to move along the guide tube and engage an end of the cable positioned therein, and a cable drive apparatus operably connected to the cross-bar. The cable drive apparatus is adapted to move the cross-bar such that the cable positioned in the guide tube is forced into the pipe.

BACKGROUND OF THE INVENTION

The present invention relates generally to thermal contractioncompensation for cables, and more particularly to an apparatus andmethod for compensating for thermal contraction of superconducting andcryo-resistive cables.

Short length demonstrator superconducting cable systems have beenassembled and tested in a number of countries worldwide. Recentdemonstrator cables have been of the high temperature superconductivity(HTSC) type with lengths typically less than 100 meters and up to amaximum of 200 meters. Earlier demonstrator cables were of the lowtemperature superconducting type and the cryo-resistive type. To beeconomically acceptable, commercial HTSC installations are required tohave similar reel lengths (500 meters to 1,500 meters) to conventionalcables to reduce the number of site assembled joints, which increase therisk of unreliable operation and which are expensive to assemble.

Conventional electric power cables with copper or aluminum conductorsare typically installed at ambient temperature, e.g. 15° C. Whencarrying the rated current, they are designed not to exceed thespecified operating temperature which is typically 90° C., a rise of 75°C. Although this increase is comparatively moderate, the expansionforces, if constrained, generate high thermomechanical forces. Forexample a stranded copper conductor having a cross sectional area of2000 millimeters² (mm²) can generate 60 kilonewtons (kN) of force.Accordingly, accessories such as joints, termination, and supportstructures have to be designed to withstand these forces and protect thecable system against damage. As a result, early cable systems were besetwith problems of thermomechanical failure of conductor connectors in“rigidly constrained” systems and fatigue failure of a cable's metallicsheath at preferential positions in “unconstrained” systems subjected tocyclic loading.

Superconducting and cryo-resistive cables experience high thermalcontraction strain when they are cooled down to their operatingtemperatures. The forces that are developed are sufficient to damage thecable, joints, and terminations. The conductor in a superconductingcable, particularly of the HTSC type is comprised of a large number ofsmall and fragile elements which have low tensile strength and aredifficult to connect together in a straight joint or termination in asufficiently robust manner to withstand long term tensile forces of highmagnitude. Additionally, the magnitude of current that can be carriedsafely in a superconducting state is limited by mechanical strain.

Insulation surrounding the conductor also contracts during cool-down andits electrical integrity is dependent upon the absence of mechanicaldisturbance and damage. The presence of thermal contraction strain inthe cable conductor and the insulation directly impacts the feasibilityand economics of HTSC cable systems in reducing the cable reel length,increasing the number of joints, reducing the current carrying capacity,and increasing the risk of electrical failure of the insulation.

Present superconducting and cryo-resistive cables operate in thetemperature range of −200° C. to −270° C. The cables are installed atnear room temperature, for example 15° C., and so they are required tocool-down through a large temperature drop of 215° C. to 285° C., thisbeing some 3-4 times greater than the temperature rise experienced byconventional cables. Thus, it is apparent that the prospective thermalcontraction forces experienced by the cable, joints, and terminationswill be 3-4 times greater than those in conventional cable systemcomponents. Because of these forces, the amount of damage that may occurto the conductor, insulation, outer cable layers, vacuum cryostat, andcoolant pressure pipes can make superconducting and cryo-resistivecables unsuitable for medium to long length commercial applications,i.e. to more than several hundred meters.

SUMMARY OF THE INVENTION

These and other shortcomings of the prior art are addressed by thepresent invention, which provides a method to eliminate or reduce themagnitude of thermomechanical contraction forces that are generated in asuperconducting or cryo-resistive cable systems when cooled down frominstallation temperatures to operating temperatures.

According to one aspect of the present invention, a method ofcompensating for thermal contraction of superconducting andcryo-resistive cables, includes the steps of determining a compensationlength for a cable such that when the cable is subjected to an operatingtemperature, the cable is in or near a stress-free state, and installingthe cable into a pipe such that portions of the cable extend outwardlypast ends of the pipe. The method further includes the steps of markingeach end of the cable such that the determined compensation length isvisibly shown, forcing the cable into the pipe at an ambientinstallation temperature such that a cable pattern is formed therein,and maintaining the cable in the pipe to prevent the cable from beingpushed out of the pipe.

According to another aspect of the present invention, a cable insertiontool includes a guide tube adapted to engage a pipe and to prevent acable positioned therein from buckling; a cross-bar adapted to movealong the guide tube and engage an end of the cable positioned therein;and a cable drive apparatus operably connected to the cross-bar, thecable drive apparatus being adapted to move the cross-bar such that thecable positioned in the guide tube is forced into the pipe.

According to another aspect of the present invention, a cable includes aduct formed by a central mandrel; a tensile member positioned in theduct; and at least one conductor laid upon the central mandrel.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter that is regarded as the invention may be bestunderstood by reference to the following description taken inconjunction with the accompanying drawing figures in which:

FIGS. 1 and 2 show how thermal contraction forces are formed in presentuncompensated HTSC and cryogenic cable systems.

FIGS. 3 and 4 show a cable compensation length to eliminate or reducethermal contraction forces according to an embodiment of the invention.

FIGS. 5 to 8 show cross-sections of cable configurations inside pipes.

FIG. 9 shows a cable formed into a helical sinusoid within a pipe tostore compensation length.

FIG. 10 shows a cable formed into a helix within a pipe to storecompensation length.

FIG. 11 shows a cable formed into a lateral deflection in a pipe bend tostore compensation length.

FIG. 12 shows a hydraulic/pneumatic ram insertion tool for inserting acompensation length of cable into a pipe.

FIG. 13 shows a chain and ratchet insertion tool for inserting acompensation length of cable into a pipe.

FIG. 14 shows a rack and pinion insertion tool for inserting acompensation length of cable into a pipe.

FIG. 15 shows a block and tackle insertion tool for inserting acompensation length of cable into a pipe.

FIG. 16 shows a cable engine insertion tool for inserting a compensationlength of cable into a pipe.

FIG. 17 shows a cable construction according to an embodiment of theinvention.

FIG. 18 shows a pipe formed into bend patterns to provide cablecompensation length.

DETAILED DESCRIPTION OF THE INVENTION

Referring to the drawings, a conventional uncompensated system is shownin FIG. 1. An HTSC or cryogenic cable system 10 with a pipe 11 extendingbetween points A and F is illustrated. Inside the pipe 11 are threespans of cable 12-14 laid end to end, A′-B′, C′-D′ and E′-F′, of nominalequal span lengths L_(s), with cable terminations T₁ and T₂ and straightjoints J₁ and J₂ which join the spans together. The positions of theterminations, T₁ and T₂, and cable joints, J₁ and J₂, are fixed inrelation to the ground. The cables 12-14 are pulled into each pipe spanA-B, C-D, and E-F, and are jointed to form a single cable 16, as shownin FIG. 2. The pipe 11 is then closed and sealed over the joints J₁ andJ₂. Coolant is introduced either into the pipe 11 or into a second pipe(not shown) that surrounds pipe 11. The cable 16 is then cooled down toits operating temperature.

As shown, if the cable lengths had not been jointed together they wouldbe free to contract a total length Δx, Equation 1, this being equivalentto a retraction of Δx/2 at the end of each cable span. In a practicalcable system the cables are jointed together and are not free tocontract, so at operating temperature the contraction strain Δx/L_(S) islocked into the cable and joints throughout the circuit length andgenerates high thermomechanical tensile forces. The total length Δx iscalculated as follows:

Δx=L _(S)·α·Δθ  Equation 1

Where Δx is the total prospective thermal retraction length in meters(m) of the cable in one pipe span; L_(S) is the initial length in meters(m) of cable at the installation ambient temperature; α is the effectivecoefficient of thermal expansion of the cable (K⁻¹); and Δθ is thetemperature change from installation to operating temperature in Kelvin(K).

As shown in FIG. 2, the thermomechanical tensile forces F_(T) and F_(J)act axially at the terminations T₁ and T₂ and the joints J₁ and J₂. Ifthe span lengths are equal and the route geometry is uniform, amagnitude of the axial tensile force F may be calculated using Equation2. The axial force is primarily generated in the main cable tensilemembers, these being the conductor(s), and the metallic sheath as thesehave a high modulus of elasticity. The axial tensile force F actsthroughout the length of the cable system and generates radial sidewallforces F_(sw) at the bends. Unless controlled by design measures, theaxial and sidewall forces are capable of damaging the conductorconnections and the insulation. The axial tensile force F and radialsidewall forces F_(sw) are calculated using the following equations:

F=K·α·Δθ  Equation 2

F _(sw) =F/R _(B)   Equation 3

Where F is the thermomechanical axial force acting in a cable or cableelement expressed in newtons (N); F_(sw) is the thermomechanicalsidewall force acting in a cable or cable element expressed innewton-meters (Nm⁻¹); K is the effective axial stiffness of a cable orcable component expressed in newtons (N); and R_(B) is the radius of abend in a cable expressed in meters (m).

Referring to FIG. 3, according to an embodiment of the invention, acompensation length Δx/2 is calculated and is marked on each end ofcable that protrudes from a pipe end to increase the cable total lengthfrom A′-B′ to A″-B″. A sufficient compensation length is provided suchthat the cable 16 will be in a mechanically stress-free state at itsoperating temperature.

As illustrated in FIG. 4 with the cable 16 jointed and installed in thepipe 11 at ambient installation temperature, the increase in cablelength has been absorbed by the formation of “cable patterns” within thepipe 11. As the cable 16 cools down, the cable 16 thermally contracts bythe same amount as the stored compensation length. Accordingly, thecable 16 is subjected to minimal tensile forces acting on the cableconductor and joint conductor connectors, minimal sidewall forces actingon the insulation at bends in the route, and minimal tensile stress inthe cable sheath to withstand high coolant pressures, e.g. 14 bar. Thus,the cable is now straight and the thermomechanical axial forces, F_(T)and F_(J) are of zero or near zero magnitude.

In some cable applications, a compromise with other aspects of cabledesign may prohibit the attainment of a completely stress-free cablesystem. In such applications the compensation length is used to reducethe tensile and sidewall forces to a magnitude that can be safelywithstood by the cable and accessories during the required service life.

The method described above may be used to achieve a calculatedcompensation length in multiple applications. For example, the methodmay be used with a single cable installed into a pipe or duct system,FIG. 5, several cables installed together into a duct or pipe system,FIGS. 6 and 7, or in applications where a cable is fitted inside ametallic sheath in the factory before it is delivered to a site, FIG. 8.

To install the cable 16 into the pipe 11, the cable is forcefully pushedinto the duct, pipe, or sheath (hereinafter collectively referred to aspipe) by the pre-calculated compensation distance, Δx, and formed into apre-designed cable pattern. The cable 16 may be pushed into the pipe 11by Δx from one joint position or preferably by Δx/2 at the two jointpositions on each end of the pipe span to induce the cable 16 to storethe compensation distance into a loose pipe. The compensation beingstored in the form of pre-calculated lateral deflections of the cable 16in relation to the axis of the pipe 11. For example, the cable 16 may bestored in a helical sinusoid pattern, FIG. 9, or a true helical pattern,FIG. 10, formed around the internal circumference of the pipe 11. In thesimplest form, the pattern would be a lateral planar deflection, FIG.11, of the cable 16 outwards at natural bends in the route geometry andin additional pre-formed bends provided for this purpose.

The cable absorption length that can be stored is controlled by the piperadial clearance ΔR_(cp) and the wavelength L_(w). The helical patternrequires the highest insertion force, but is capable of absorbing a longcable compensation length. The helical sinusoid requires a lowerinsertion force, with a medium capability to store cable compensationlength. The lateral deflection of the cable in a pipe bend requires thelowest insertion force and is capable of absorbing a high cablecompensation length. The length that can be stored in pre-formed pipebends, FIG. 11 and FIG. 18, is proportional to the product of the numberof bends, the radial clearance ΔR_(cp) and the bend angle φ. Thecompensation storage patterns are preferably pre-designed using an FEAdynamic computation technique which will model the behavior of the cablein the particular route geometry comprising natural bends and inclines.In cases of simple routes which have neither bends nor inclines thedesign may be achieved using mathematical algorithms. A key part of theformation of the patterns is the achievement of elastic buckling at lowaxial force during installation. Elastic buckling is a reversiblegeometric deformation that permits the cable to re-straighten when it iscooled and which permits the pattern to reform when the cable re-heatsto ambient temperature. For example, during a planned maintenanceprocedure, or an unplanned cable system fault.

To reduce the amount of force needed to push the cable into a pipe, theouter surface of the cable and the inner surface of the pipe may becoated with a combination of materials to minimize longitudinalfriction, and achieve a unified distribution of stored compensationstrain in the cable along the pipe span length. The inner surface of thepipe may be coated with a low friction material containingpoly-tetra-flouro-ethylene (PTFE). Alternatively, or in combination, thecable may be provided with a polymeric extruded jacketing material ofhigh shore hardness, such as a medium to high density grade ofpolyethylene (PE), a polypropylene jacket, a nylon jacket or a nylonco-extruded jacket on a base of PE. The surfaces may also be lubricatedat the time of installation with, for example, a synthetic or naturalwax based solution or a graphite based dry powder.

To aid in inserting a cable into a pipe, as described above, cableinsertion tools, FIGS. 12-16, may be used to achieve a calculated cablecompensation distance. In each of the tools described below, a temporaryguide tube may be connected to the end of the pipe span. The guide tubeprovides a close fit to the cable to prevent it from locally bucklingwhen pushed into the pipe and may be terminated with “bell mouths” toprotect the cable from excessive bending. The insertion tools of FIGS.12-15 apply an axial force via an end cap and are suitable for use withall superconducting or cryo-resistive cable constructions.

Referring to FIG. 12, a hydraulically or pneumatically powered insertiontool is shown at reference numeral 100. The insertion tool 100 includesa guide tube 110 having opposing longitudinal slots (not shown) to allowa cross-bar 111 to slide axially along the guide tube 110 and to engagea cable 112 and an end cap 113. A cable drive apparatus 115 forces thecable 112 into the pipe 130 and includes connecting rods 114, 116 andrams 121, 123. Connecting rods 114 and 116 are connected to opposingends of the cross-bar 111. Connecting rod 114 connects a first end 117of the cross-bar 111 to a first piston 120 of ram 121, and connectingrod 116 connects a second end 118 of the cross-bar 111 to a secondpiston 122 of ram 123. The rams 121 and 123 are integral with an endplate 124 of the insertion tool 100 and may be hydraulically orpneumatically powered.

In use, after installation into a pipe 130, the cable 112 is cut andterminated with the end cap 113, similar to that shown in FIG. 17. Byusing the end cap 113, each layer of the cable 112 is mechanicallygripped to uniformly distribute compressive and tensile force.Sufficient cable length is provided to accommodate the compensationlength and the joint length. The operator marks positions on the guidetube of the initial cable end position, the specified compensationdistance, and the final cable end position. Liquid or gas pressure isapplied to the rams 121, 123 and the cable 112 is pushed into the pipe130 by the specified distance.

The above process is preferably performed simultaneously at both ends ofthe pipe 130. If the process is only performed at one end of the pipe130, then the cable 112 is clamped at the opposite end of the pipe 130to prevent outwards movement. After cable insertion is completed, theends of the cable 112 are clamped to the pipe 130 to prevent compressiveforces in the cable 112 from pushing the cable 112 back out of the pipe130. A clamp 131 is located between the pipe 130 closure flange 132 andthe insertion tool end plate 124, such that after tightening the clamp131 to grip the cable 112, the guide tube 110 may be removed. The jointbetween the adjacent cable lengths is then assembled. The clamps 131 maythen either be removed or left permanently in position to protect thejoint from movement due to any differential cable forces that may occurin service operation.

As shown in FIG. 13, a chain and ratchet powered insertion tool isillustrated at reference numeral 200. The insertion tool 200 is similarto insertion tool 100 except insertion tool 200 uses a chain and ratchetcable drive apparatus 215 to force a cable 212 into a pipe 230. Likeinsertion tool 100, insertion tool 200 includes a guide tube 210, across-bar 211, and an end plate 224. Unlike insertion tool 100,insertion tool 200 uses twin flexible drive chains 214 and 216 connectedat opposing ends of cross-bar 211. Drive chain 214 connects a first end217 of the cross-bar 211 to a first ratchet 221 having a sprocket 220, ahandle 226 and a pawl 227. Drive chain 216 connects a second end 218 ofthe cross-bar 211 to a second ratchet 223 having a sprocket 222, ahandle 228 and a pawl 229. It should be appreciated that the handles226, 228 may be replaced with motors or other means for rotating thesprockets 220 and 222. Upon rotation of the sprockets 220 and 222, thechains 214 and 216 are drawn around the sprockets 220 and 222 and thecable end is pushed into the pipe 230.

Referring to FIG. 14, a rack and pinion gear insertion tool is shown atreference numeral 300. The insertion tool 300 is similar to insertiontool 100 except insertion tool 300 uses a rack and pinion cable driveapparatus 315 to force a cable 312 into a pipe 330. Like insertion tool100, insertion tool 300 includes a guide tube 310, a cross-bar 311, andan end plate 324. The insertion tool further includes twin toothed racks314 and 316 connected to opposing ends of cross-bar 311. Rack 314connects a first end 317 of the cross-bar 311 to pinion gear 320, andrack 316 connects a second end 318 of the cross-bar 311 to pinion gear322. The pinion gears 320 and 322 are rotated by motors 321 and 323,respectively, such that the racks 314 and 316 are drawn towards thepipe's 330 closure flange 332, thereby pushing the cable into the pipe330. It should be appreciated that the pinion gears 320 and 322 may belocated on the cross-bar 311 and the racks 314 and 316 fixed to theinsertion tool end plate 324.

A block and tackle pulley insertion tool is shown in FIG. 15 atreference numeral 400. The insertion tool 400 is similar to insertiontool 100 except insertion tool 400 uses a twin block and tackle cabledrive apparatus 415 to force a cable 412 into a pipe 430. Like insertiontool 100, insertion tool 400 includes a guide tube 410, a cross-bar 411,and an end plate 424. Unlike insertion tool 100, insertion tool 400 usespulleys 414 and 416 connected at opposing ends of cross-bar 411 andpulleys 420 and 422 connected to opposing ends of the end plate 424.Pulley 414 is connected to a first end 417 of the cross-bar 411 and isconnected to pulley 420 by a rope 421. Pulley 416 is connected to asecond end 418 of the cross-bar 411 and is connected to pulley 422 by arope 423. Ropes 421 and 423 each include a terminated end 434, 435 and afree end 436, 437, respectively. It should be appreciated that the ropes421 and 423 may be of a high strength, low stretch material such asstranded steel, Kevlar or any other suitable material. Further, itshould be appreciated that the term rope is being used generally and mayinclude cables, bands, or other suitable devices for interacting withand between pulleys. Free ends 436 and 437 of ropes 421 and 423,respectively, may be pulled by using any suitable means, such as by amotor powered capstan, to draw the ropes 421 and 423 through the pulleysystem, thereby pushing the cable 412 into the pipe 430.

Referring to FIG. 16, a cable engine insertion tool is shown atreference number 500. In addition to the insertion tools describedabove, the cable compensation length of cable 512 may be pushed into thepipe 530 by either one or a series of conventional designs of cableengine, such as the caterpillar cable engine shown. In this scenario, acable engine 510 is located at both the input and output end of the pipespan such that both engines 510 simultaneously push the cable 512inwards. To overcome the effect of friction in long pipe spans, the pipe530 may be temporarily subdivided into shorter sections to provide thedistance necessary to locate additional cable engines, without the needto cut and subsequently joint the cable. After the required cablecompensation length has been pushed into the pipe 530, the pipe 530 isclosed and sealed at the intermediate positions.

In addition to using insertion tools, like those disclosed above, othermeans may be used to aid the process of inserting a cable into a pipe.For example, vibration may be applied to the pipe during or after thecable insertion operation. The use of vibrations help reduce theinsertion force needed and help uniformly distribute the compensationlength. Based on finite element analysis, it has been shown, forexample, that a vibration of frequency 13 Hz and magnitude 0.032 mm issufficient to momentarily lift a cable from the constraint of gravityand friction and permit stored compressive strain to move the cablealong the pipe. The vibration may be applied by a powered vibration toolapplied to the pipe at a number of positions according to the spanlength. The vibration tool may be, for example, an electronicallypowered transducer or a motor driven eccentrically loaded rotor disc.

In another example, an impulsive shock may be applied to the cableduring or after the cable insertion process to reduce the insertionforce and uniformly distribute the compensation length. A pulse ofelectric current applied along a conductor in the cable produces amomentary electro-mechanical impulsive force of sufficient magnitude tomomentarily lift the cable from the constraint of gravity and frictionand permit stored compressive energy to move the cable along the pipe. Aparallel return conducting path is required to return the pulse ofcurrent, such as along two or more cables in one pipe, or in the case ofone cable in the pipe, a second temporary cable laid either inside oroutside the pipe.

The impulsive force results from the interaction of the magnetic fieldfrom one conductor with the current in the second conductor. Theadvantages of this are that the cable is lifted throughout the length ofthe pipe and it is unnecessary to provide external access to the pipe orto distribute mechanical vibrating machines along the pipe. Themagnitude of the current may be calculated to suit the particular cableunit weight. For example, a simultaneous current pulse of peak magnitude28 kA and 5×10⁻³ seconds duration applied to three heavy 230 kV, 2500kcmil transmission class cables is sufficient to momentarily lift themand permit longitudinal movement. The current pulse may be applied byeither discharging a charged capacitor, discharging the cableinsulation, or short circuiting the output of a spinning generator alongthe cable through a suitable series impedance.

Referring to FIG. 17, in another embodiment of the invention, a cable isshown at reference numeral 600. The cable 600 includes a central mandrel602 forming a duct 610. A tensile member 601 in the form of a ropeselected to have the properties of low extension under load (highelastic modulus) and high tensile strength, such as a steel rope, analuminum alloy rope or a Kevlar rope is inserted into the duct 610 ofthe central mandrel 602. An outer surface 603 of the rope 601 may bejacketed and an inner surface 604 of the duct 610 may be formed of, orlined with, materials selected to reduce longitudinal friction.

The flexible tensile member 601 is tightened after installation andbefore jointing to provide the cable compensation length bylongitudinally compressing the cable 600 construction and forcing thecable 600 to initiate the formation of lateral patterns, therebyrelieving the cable 600 and its joints and terminations fromexperiencing an unacceptable magnitude of tensile load at cableoperating temperature. The tightening of the tensile member 601 may beperformed in combination with the cable insertion process describedabove to reduce the insertion force and achieve a uniform distributionof patterns. Clamps are applied to the cable 600 at each end of the pipe630 to prevent the compressed cable 600 from moving. The tensile member601 is then released at one or both cable ends and the cables arejointed together. During cool-down the stored cable compensation lengthis released to cancel the thermal contraction strain and to eliminatetensile thermomechanical forces.

The cable 600 construction is designed such that it may be axiallycompressed during the cable insertion process and extended during thecable cool-down. The cable's 600 low axial modulus is achieved by usinga flexible central mandrel upon which inner and outer conductors 606,608 are laid, both longitudinally and radially. The conductors 606 and608 are applied at short lay angles with low compaction and withdiscrete interstitial gaps between the wires and tapes. The inner andouter conductors 606, 608 and their internal successive layers of wiresor tapes are applied in a uni-lay direction, and insulation 607 isformed of a longitudinally deformable material, for example, an extrudedelastomeric insulation with a low temperature, low modulus of elasticitysuch as a silicone elastomer or an EPR elastomer, or a tapedconstruction of laminate or Kraft paper insulation separated by suitablysized butt gaps. A metallic sheath 609 with a thin corrugated wall and ashort pitch, for example, 1 mm thick sheet stainless steel is also used.

In addition to achieving an axially compressible construction, theuni-lay conductor 600 produces a non-torque balanced cable that willreadily form spiral helices under the action of low compressive force.During installation into the pipe the cable is protected from beingextended by restricting the pulling tension to a minimal value suitablefor cable guidance only and by the use of a cable engine or distributedengines as described above. The use of the cable construction with atensile member 601 inside a duct 610 of the mandrel 602 permits thecable 600 to be pulled into the pipe from its leading end without riskof extension. During the pull the tensile member 601 is connected to thecable ‘pulling bolts’ (pulling eyes) connected to each end of the cable,such that the member 601 withstands the tension and protects the cable600 from extension. The cable 600 is then clamped, the internal memberis released, and the cables are jointed together.

Referring to FIG. 18, a method of pre-forming a pipe into a series ofpermanent bends is shown at reference numeral 700. By pre-forming a pipewith a series of bends, the pipe is able to accommodate the cablecompensation length by the cumulative outward deflection of the cable ineach bend, as illustrated in FIG. 11. The compensation length isdirectly proportional to the product of the number of bends, the bendangle φ, and the diametral clearance between the cable and the pipeΔR_(cp). After installation of the cable into the pipe the cablecompensation length is pushed into the pipe using one of the cableinsertion methods described above. The cable is moved outwards andupwards to the outer wall of the bends as shown in FIG. 11, therebyaccommodating the increased length B-B′. During cool-down the cablelength contracts to length C-C′ such that it moves to contact the innerside of the pipe bend thereby releasing the maximum compensation length,this being the difference between B-B′ and C-C′. The radius R_(B) of thepipe bend is selected to be greater than the minimum permitted bendingradius of the cable.

The cable may alternatively be installed without being forcefullyinserted outwards into the pre-formed bends. In this instance, the cableis inserted a sufficient distance to lie on the neutral axis of the pipeA-A′ such that 50% of the prospective distance is released when thecable moves to the inner wall of the bend, C-C′ during cooldown. Theadvantages of this method are that the pipe bends control the uniformdistribution of bending along the cable length, a comparatively smallpipe diameter may be selected, and longitudinal cool-down stresses inthe pipe are reduced.

It should also be appreciated that the pipe may be elastically deformedduring installation into temporary bends. The initial increase in cablelength compared to the straight span length provides the compensationlength. During cool-down the elastic pipe deformation is progressivelyreleased such that the pipe and cable become straight. This allows thepipe to temporarily accommodate the compensation distance by increasingthe pipe length, such that the distance A, B, C, D . . . Q is greaterthan the straight span length L_(S). This can be advantageous when thecable is required to be a tight fit in the pipe or metallic cablesheath. This is particularly suited for cable applications that provideaccessibility to the pipe, for example, those above ground or in atunnel. The maximum amplitude of the patterns is dictated by the safebending strain for the pipe. The amplitude may be increased by use of acorrugated pipe or metallic cable sheath exhibiting low bendingstiffness or the insertion into the pipe at regular intervals oflongitudinal flexible bellows. The pipe amplitude may be achieved by theuse of a conventional pipe bending tool in which the pipe is anchored attwo closely spaced half wavelength points. The pipe is then deflectedoutwards by a hydraulic ram pressing on a curved shoe. The pipe systemis held in the deformed shape by temporary distributed clamps.

The cable is next installed into the deformed pipe. The differencebetween the length A . . . Q and L_(S) provides the compensation length.The joints are then made to connect the ends of the cables together andthe pipe is closed. During cool-down the positions of the temporary pipeclamps are progressively relaxed to permit the pipe patterns to moveelastically inwards back to the original straight length. When the cableis required to be re-heated to ambient temperature, the temporary cleatsare re-applied and pulled back to their original positions as thetemperature rises. Alternatively the cleats may be left permanently inposition and be restrained by steel springs, such that the positions ofthe temporary pipe clamps are progressively relaxed to permit the pipepatterns to move elastically inwards back to the original straightlength. When the cable is required to be re-heated to ambienttemperature, the temporary cleats are re-applied and pulled back totheir original positions as the temperature rises. Alternatively, thecleats may be left permanently in position and be restrained by steelsprings, such that upon cooling the pipe straightens and extends thesprings and upon re-heating, the pipe expands and is pulled back intothe original pattern.

The foregoing has described an apparatus and method for compensating forthermal contraction of superconducting and cryo-resistive cables. Whilespecific embodiments of the present invention have been described, itwill be apparent to those skilled in the art that various modificationsthereto can be made without departing from the spirit and scope of theinvention. Accordingly, the foregoing description of the preferredembodiment of the invention and the best mode for practicing theinvention are provided for the purpose of illustration only and not forthe purpose of limitation.

We claim:
 1. A cable insertion tool, comprising: (a) a guide tubeadapted to engage a pipe and to prevent a cable positioned therein frombuckling; (b) a cross-bar adapted to move along the guide tube andengage an end of the cable positioned therein; and (c) a cable driveapparatus operably connected to the cross-bar, the cable drive apparatusbeing adapted to move the cross-bar such that the cable positioned inthe guide tube is forced into the pipe.
 2. The cable insertion toolaccording to claim 1, further including an end plate adapted to restadjacent to a flange of the pipe.
 3. The cable insertion tool accordingto claim 1, wherein the cable drive apparatus includes a first connectorextending between a first end of the cross-bar and a first piston of afirst ram and a second connector extending between a second end of thecross-bar and a second piston of a second ram.
 4. The cable insertiontool according to claim 3, wherein the first and second rams arehydraulically powered.
 5. The cable insertion tool according to claim 3,wherein the first and second rams are pneumatically powered.
 6. Thecable insertion tool according to claim 1, wherein the cable driveapparatus includes a first chain extending between a first end of thecross-bar and a first ratchet and a second chain extending between asecond end of the cross-bar and a second ratchet.
 7. The cable insertiontool according to claim 6, wherein the first and second ratchets eachinclude a sprocket and a pawl.
 8. The cable insertion tool according toclaim 1, wherein the cable drive apparatus includes a first pulleyconnected to a first end of the cross-bar, a second pulley connected toa first end of an end plate, a third pulley connected to a second end ofthe cross-bar, and a fourth pulley connected to a second end of the endplate.
 9. The cable insertion tool according to claim 8, wherein a firstrope extends between and around the first pulley and the second pulleyand a second rope extends between and around the third pulley and thefourth pulley.
 10. The cable insertion tool according to claim 1,wherein the cable drive apparatus includes a first rack driven by afirst pinion and a second rack driven by a second pinion, the first rackbeing connected to a first end of the cross-bar and the second rackbeing connected to a second end of the cross-bar.
 11. The cableinsertion tool according to claim 10, wherein the first pinion is drivenby a first drive means and the second pinion is driven by a second drivemeans.
 12. The cable insertion tool according to claim 11, wherein theguide tube includes a flared end to protect the cable from excessivebending.